Fastener delivery and installation system

ABSTRACT

A fastener delivery and installation system is provided that comprises an end effector mounted on an automated machine and operable to drill a hole through a workpiece and insert a fastener through the hole, and a fastener feed unit operable with the automated machine to deliver the fasteners through the end effector and into the workpiece. Further, a hand-held tool is operable against a second surface of the workpiece and is aligned with the end effector. Once the hand-held tool is positioned properly, a magnetic field is generated and the workpiece is clamped to enable the end effector to drill a hole through the workpiece and insert a fastener therethrough. Additionally, a detector is located on the hand-held tool for generating guidance information to inform an operator where to move the hand-held tool so as to align the hand-held tool with the end effector.

FIELD OF THE INVENTION

The present invention relates generally to fastening equipment and moreparticularly to equipment and methods for drilling holes through aworkpiece, delivering fasteners to the workpiece, and installing thefasteners into the holes.

BACKGROUND OF THE INVENTION

In the production assembly of aircraft, the majority of substructuresuch as fuselage frames and longerons, along with wing spars and ribs,are joined to the skin of the aircraft with thousands of fasteners.Further, a plurality of fastener types, along with variations indiameters and grip lengths, are typically used in an aircraft assemblyor subassembly. (Generally, a fastener grip length refers to thecumulative thickness of the parts that the fastener holds together).Installation of fasteners in relatively large aircraft substructures andskins is typically performed either manually or by automated fasteningequipment.

Manufacturing equipment that automatically delivers fasteners to aworkpiece, or a fastening device, is typically employed in high rateproduction environments. The equipment generally comprises a storagedevice for the fasteners and a mechanism or system that transportsfasteners from the storage device to the workpiece or fastening device.For example, U.S. Pat. No. 5,588,554 to Jones, the contents of which areincorporated herein by reference in their entirety, discloses a devicefor delivering fasteners to a workpiece comprising a suction head thatremoves fasteners from a storage area and delivers the fasteners througha delivery tube using a vacuum. The fasteners are individually stored inholes of a predetermined or fixed depth, and only one fastener may bestored in any given hole. Accordingly, each hole contains a fastener ofa specific configuration, diameter, and grip length.

Yet another known art fastener delivery system is disclosed in U.S. Pat.No. 5,193,717 to Rink et al., wherein rivet cartridges are unloaded andrivets are delivered to a rivet machine or the like with pressurizedair. The rivet cartridges are filled off line by a rivet pump thatreceives rivets from a vibrating bowl feeder, and the fasteners aredelivered through a common passageway to a fastener installation tool.However, the fastener delivery system of Rink et al. requires a separatefastener escapement mechanism to remove and deliver the fasteners.

Additionally, manual fastener installation can be time consuming andcumbersome. Generally, an operator must first determine the appropriatefastener type and diameter from a blueprint or other manufacturing workinstruction delivery system. Due to manufacturing variations inindividual part fabrication and assembly positioning variations, theproper grip length of the fastener is often determined by manuallymeasuring hole depths. Once the proper fastener configuration isdetermined, the fastener stock must then be located and selected fromfastener bins, which are typically stored at a common location near thework station. A limited number of fasteners are then moved by hand fromthe fastener bins to the work station and are generally staged withinthe reach of an operator. If permitted by the work environment, severalfasteners are stored in a pouch that is secured around the waist of anoperator. Accordingly, the operator sorts through the fasteners toselect the proper configuration and inserts the fastener directly into ahole through the parts or inserts the fastener into an installation toolthat installs the fastener through the parts. As a result, a significantamount of time is spent by an operator determining the proper fastenerconfiguration, locating the fastener within a storage bin, andtransporting the fastener to the work station for installation.Therefore, manual fastener installation procedures are time consumingand thus costly.

Accordingly, a need remains in the art for a fastener delivery andinstallation system that efficiently delivers and installs fasteners toa work station or workpiece where parts are being assembled. Thefastener delivery and installation system should be capable ofdelivering a plurality of different fastener configurations and shouldfurther be capable of automatically selecting the proper fastenerconfiguration from a variety of inputs. Additionally, the fastenerdelivery system should also be capable of maintaining a record offastener inventory that is preferably integrated with existingproduction manufacturing systems.

SUMMARY OF THE INVENTION

In one preferred form, the present invention provides an apparatus fordelivering and installing fasteners to and through a workpiece thatcombines an automated machine and a fastener feed unit disposed on oneside of the workpiece and a hand-held tool that is manipulated by anoperator on the opposite side of the workpiece. The automated machinecomprises an end effector supporting tools such as a drill for drillinga hole through the workpiece and a riveter for installing a rivet intothe hole. Additionally, a controller positions and activates theautomated machine, the end effector, and the fastener feed unit duringoperation of the apparatus.

The fastener feed unit comprises an unloading mechanism in communicationwith a fastener storage device, wherein a control system activates theunloading mechanism to remove a specific fastener configuration from thefastener storage device and transport the fastener to a deliveryconduit, where the fastener is caused to be delivered through thedelivery conduit, through the end effector, and into a hole in theworkpiece, preferably using a pneumatic source. The fastener storagedevice is generally a fastener cassette that comprises a plurality offastener storage tubes that house the fasteners. Each fastener storagetube houses a specific fastener configuration, which includes thefastener type (i.e. hi-lok, jo-bolt, rivet), diameter, and grip length.Accordingly, the fastener storage tubes range in diameter correspondingto the specific fastener configuration housed therein. Furthermore, thefastener storage device is removable from the fastener feed unit tofacilitate ease of replacement when additional types of fasteners may berequired or when the fastener storage device is moved to anotherapparatus. Moreover, a plurality of fastener cassettes may be used asnecessary within the fastener feed unit.

The automated machine further comprises a guide structure, such as apair of guide rails, adapted to be releasably affixed to or adjacent tothe workpiece, along with an end effector carriage and a fastenercarriage that travel along the guide structure and support the endeffector and the fastener feed unit, respectively. Accordingly, the endeffector and the fastener feed unit can be positioned in a desiredlocation along the surface of the workpiece where a fastener is to beinstalled. Alternately, the fastener feed unit may be disposed at afixed location while the end effector moves along the guide structure.The end effector further comprises an electromagnetic clamping devicethat generates a magnetic field and a positioning device that generatesa positioning signal detectable on the opposite side of the workpiece.

The hand-held tool comprises a magnetic clamping block, such as a steelblock or the like. When the magnetic clamping block is placed againstthe opposite surface of the workpiece on the side opposite from the endeffector, the magnetic field of the clamping device causes the clampingblock to be attracted toward the clamping device, thereby clamping theworkpiece therebetween. The hand-held tool further comprises a detectorfor detecting the positioning signal of the positioning device, whereinthe detector is operable to generate guidance information for anoperator. Further, the hand-held tool may include a visual display fordisplaying the guidance information in graphical, audible, or otherforms. Once the hand-held tool is aligned with the end effector, thecontroller activates the end effector and the fastener feed unit todrill a hole in the workpiece and to further deliver and install afastener into the hole.

After fastener installation is complete, the end effector is operable tosignal the operator that the operation is complete. The operator maythen deactivate the hand-held tool such that the automated machine (andalso the fastener feed unit if required) may be moved to a new locationfor subsequent fastener installations. Alternately, the end effector mayautomatically deactivate the electromagnetic clamping device onceinstallation of the fastener is complete such that no action of theoperator is required to release the clamping force on the workpiece.

As used herein, the term “workpiece” should be construed by thoseskilled in the art to be one or more parts or workpieces that are beingassembled at a given location, for example a wing spar to a wing skin,or a fuselage frame to a fuselage skin. Accordingly, the term“workpiece” should not be limited to a single part or workpiece.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter. It shouldbe understood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a perspective cutaway view of a fastener delivery andinstallation system in accordance with the present invention;

FIG. 2 is an enlarged view of a portion of FIG. 1 showing the fastenerdelivery and installation system in greater detail in accordance withthe present invention;

FIG. 3 is a perspective view of the fastener delivery and installationsystem in use on a wing box in accordance with the present invention;

FIG. 4 is a block diagram of the fastener delivery and installationsystem in accordance with the present invention; and

FIG. 5 is a perspective view of a fastener feed unit in accordance withthe present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiments is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

Referring to the drawings, an apparatus according to the presentinvention is illustrated and generally indicated by reference numeral 10in FIGS. 1 through 4, which is also referred to as a fastener deliveryand installation system 10. The fastener delivery and installationsystem is comprised of an automated machine 12 for installing fastenersin a workpiece, as shown and described in copending application titled“Apparatus and Method for Installing Fasteners in a Workpiece,” Ser. No.09/522,222 now U.S. Pat No. 6,357,101, which is commonly assigned withthe present application and the contents of which are incorporatedherein by reference. The fastener delivery and installation systemfurther comprises a fastener feed unit 14, which is shown and describedin copending application titled “Portable Automatic Fastener DeliverySystem,” Ser. No. 09/931,501 now U.S. Pat. No. 6,688,489, which is alsocommonly assigned with the present application and the contents of whichare incorporated herein by reference.

FIGS. 1 and 2 show the fastener delivery and installation system 10 inuse with a fuselage section of an airframe, and FIG. 3 shows thefastener delivery and installation system 10 in use with a wing sectionof an airframe. FIG. 4 is a block diagram of the fastener delivery andinstallation system 10 with its constituent components which aredescribed in greater detail below.

As shown, the fastener delivery and installation system 10 comprises theautomated machine 12 and the fastener feed unit 14 disposed on one sideof the workpiece (i.e., fuselage, wing), also referred to as a firstside of the workpiece, and a hand-held tool 16 disposed on the otherside of the workpiece, or along a second surface of the workpiece. Theautomated machine 12 is preferably supported on a guide structure 18that advantageously can be releasably attached to the workpiece. In theillustrated embodiment, the guide structure 18 comprises a pair ofparallel guide rails 20 affixed to the first surface of the workpiece bysuction cups 22. The guide structure 18 could instead be affixed to theworkpiece by bolts or the like, or could be supported without beingattached to the workpiece, as long as the guide structure 18 is fixedrelative to the workpiece.

The automated machine 12 further comprises an end effector 24 that isused to perform operations such as drilling a hole through the workpieceand installing a fastener into the hole. The end effector 24 issupported within an end effector carriage 26 that rides along the rails20, and similarly, the fastener feed unit 14 is supported within afastener carriage 28 that also rides along the rails 20. Alternately,the fastener feed unit 14 may be positioned at a fixed location on orproximate the rails 20 while the end effector carriage 26 rides alongthe rails to install subsequent fasteners. The end effector 24advantageously comprises a drill 24 a, a conduit 24 b through whichfasteners are delivered from the fastener feed unit 14, and/or a riveter24 c, which may be an electromagnetic riveter (EMR) or other device foruse in installing other types of fasteners such as hi-loks or jo-bolts,among others. The end effector 24 may also comprise an impact hammer 24d or the like for forcing a lock bolt or similar type of fastenerthrough a hole drilled through the workpiece. Any one of the varioustools 24 a-d of the end effector 24 can be moved into a working positionaligned with a target location on a workpiece where a fastener is to beinstalled, while the other tools are held in stand-by position, and theselected tool can be operated to perform an operation on the workpiece.Operation of the end effector 24 and the hand-held tool 16, includingthe detector, the processor, and the display, among others, is describedin greater detail in copending application Ser. No. 09/522,222 now U.S.Pat. No. 6,357,101, the contents of which have been incorporated byreference, and therefore such operation is not described herein.

As further shown, the fastener feed unit 14 is in communication with theautomated machine 12 through a delivery conduit assembly 30, throughwhich fasteners are delivered from the fastener feed unit 14 to theautomated machine 12. Generally, the fasteners are delivered through adelivery conduit 30 a, which is preferably a flexible material and thelength of which may be adjusted according to specific applicationrequirements, to the end effector 24 and through the end effectorconduit 24 b for installation through the workpiece.

Preferably, the hand-held tool 16 comprises a command signal generator32 as shown in FIG. 4, which can be activated by the operator, such asby pulling a trigger or operating a similar type of switch device. Thecommand signal generator 32 generates a command signal that is receivedby the automated machine 12, and more specifically by a controller 34that positions and activates the automated machine 12, the end effector24, and the fastener feed unit 14. For example, the command signalgenerator 32 may transmit an RF signal, and the controller 34 mayinclude a receiver for receiving the RF signal, thereby facilitatingcommunication between the operator and the controller 34.

Referring now to FIG. 5, the fastener feed unit 14 according to thepreferred form of the present invention is shown in greater detail. Thefastener feed unit 14 comprises an unloading mechanism 40 incommunication with a fastener storage device 42, wherein the controller34 (not shown) causes the unloading mechanism 40 to remove a fastenerhaving a specific configuration from the fastener storage device 42 andtransport the fastener to the delivery assembly conduit 30, wherein thefastener is delivered to the end effector 24 (not shown). The fastenerfeed unit 14 generally removes and delivers fasteners using a pneumaticsource 44, which is preferably 90 psi (pounds per square inch) shop air.The pneumatic source 44 is activated by the controller 34 and is incommunication with both the unloading mechanism 40 and the deliveryconduit assembly 30 through flexible tubing 46. (The fittings thatconnect the pneumatic source 44 and the flexible tubing 46 are not shownfor clarity). The pneumatic source 44 activates one or a plurality ofvacuum generators 48 to remove a fastener from the fastener storagedevice 42 and secure the fastener within the unloading mechanism 40.Once the fastener is secured within the unloading mechanism 40, thecontroller 34 positions the unloading mechanism 40 adjacent the deliveryconduit assembly 30, wherein the vacuum generators 48 are deactivatedand the fastener falls and is transported through the delivery conduit30 a by gravity and by pressurized air from the pneumatic source 44.Operation of the fastener feed unit 14, including the delivery conduitassembly 30, the fastener storage device 42, and the unloading mechanism40, among others, is described in greater detail in copendingapplication Ser. No. 09/931,501 now U.S. Pat. No. 6,688,489, which asbeen incorporated by reference, and thus are not further describedherein for purposes of clarity.

In operation, the controller 34 activates the end effector 24 togenerate a magnetic field for clamping the workpiece between the endeffector 24 and the hand-held tool 16. The controller 34 then activatesthe end effector 24 to drill a hole through the workpiece. After thehole is drilled, the controller 34 activates the fastener feed unit 14to deliver the required fastener through the delivery conduit assembly30, through the end effector 24, through the end effector conduit 24 b,and into the hole in the workpiece. Next, the controller 34 activatesthe end effector 24 to install the fastener in the hole using, forexample, the impact hammer 24 d. When installation of the fastener iscompleted, the controller 34 can signal the operator to deactivate themagnetic field produced by the end effector 24 so that the automatedmachine 12, and the fastener feed unit 14 if applicable, can be movedalong the rails 20 to the next location at which a fastener is to beinstalled.

The automated machine 12 preferably comprises a powered drive device 50(FIG. 4) for moving the automated machine 12 and/or the fastener feedunit 14 along the rails 20 to a new location. The powered drive device50 advantageously is controlled by the controller 34 so as to accuratelyposition the automated machine 12 and/or the fastener feed unit 14 in apredetermined location along the workpiece. Further, the controller 34may comprise a control system as shown and described the copendingapplication Ser. No. 09/931,501 now U.S. Pat. No. 6,688,489, which hasbeen incorporated by reference, or the control system may be a separatecomponent of the fastener delivery and installation system 10 that is incommunication with the controller 34. The design of a suitablecontroller 34 and/or control system is well within the capabilities of amachine designer of ordinary skill in the art of automated machinedesign and thus will not be further described herein.

Although the present invention discloses a system for the delivery offasteners, other types of components may also be removed and deliveredaccording to the teachings of the present invention for a variety ofapplications. For example, the system may be employed to deliver detailparts for an assembly or even components for other applications such asfood delivery, mail delivery, and a wide range of other applications.Accordingly, the delivery and installation of fasteners for aircraftassembly operations shall not be construed as limiting the scope of thepresent invention.

The description of the invention is merely exemplary in nature and,thus, variations that do not depart from the substance of the inventionare intended to be within the scope of the invention. Such variationsare not to be regarded as a departure from the spirit and scope of theinvention.

What is claimed is:
 1. An apparatus for delivering and installingfasteners to and through a workpiece comprising: an automated machinemovable along a first surface of the workpiece; an end effector mountedon the automated machine and operable to drill a hole through theworkpiece and insert a fastener through the hole, the end effectorcomprising an electromagnetic clamping device that generates a magneticfield; a positioning device located proximate the end effector andoperable to generate a positioning signal that is detectable proximate asecond surface of the workpiece on an opposite side from the firstsurface; a fastener feed unit operable with the automated machine todeliver the fasteners through the end effector and into the workpiece; acontroller that positions and activates the automated machine, the endeffector, and the fastener feed unit; a hand-held tool comprising amagnetic clamping block disposed against the second surface of theworkpiece and aligned with the electromagnetic clamping device, whereinwhen the magnetic field is generated, the workpiece is clamped betweenthe magnetic clamping block and the electromagnetic clamping device toenable the end effector to drill a hole through the workpiece and inserta fastener therethrough; and a detector located on the hand-held toolfor detecting the positioning signal and for generating guidanceinformation to inform an operator where to move the hand-held tool so asto align the magnetic clamping block with the electromagnetic clampingdevice.
 2. The apparatus according to claim 1, wherein the fastener feedunit further comprises: a fastener storage device; an unloadingmechanism in communication with the fastener storage device; and adelivery conduit in communication with the unloading mechanism and theautomated machine, wherein the controller activates the unloadingmechanism to retrieve at least one fastener from the fastener storagedevice, thereby causing the fastener to be transported through thedelivery conduit and to the end effector.
 3. The apparatus according toclaim 1, wherein the hand-held tool further comprises a command signalgenerator operable to generate a command signal upon activation by theoperator, and the end effector being operable to receive the commandsignal and to activate the electromagnetic clamping device to generatethe magnetic field such that the electromagnetic clamping device and themagnetic clamping block clamp the workpiece therebetween.
 4. Theapparatus according to claim 1, wherein the hand-held tool furthercomprises a visual display for displaying the guidance information. 5.The apparatus according to claim 1, wherein the automated machinefurther comprises: a guide structure fixed relative to the workpiece,the guide structure comprising at least one guide member extending alongthe first surface; an end effector carriage mounted on the guidestructure and movable along the guide member, the end effector beingmounted on the carriage; and a fastener carriage mounted on the guidestructure and movable along the guide member, the fastener feed unitbeing mounted on the carriage.
 6. The apparatus according to claim 5,wherein the guide structure comprises a pair of parallel guides alongwhich the carriages move.
 7. The apparatus according to claim 5, whereinthe guide structure is releasably attachable to the workpiece.
 8. Theapparatus according to claim 1, wherein the fastener storage devicefurther comprises at least one fastener cassette that is removablydisposed within the fastener feed unit.
 9. The apparatus according toclaim 8, wherein the fastener cassette further comprises a plurality offastener storage tubes that house a plurality of fastenerconfigurations.
 10. An apparatus for delivering and installing fastenersto and through a workpiece comprising: an automated machine movablealong a first surface of the workpiece; an end effector mounted on theautomated machine and operable to drill a hole through the workpiece andinsert a fastener through the hole, the end effector comprising anelectromagnetic clamping device that generates a magnetic field; apositioning device located proximate the end effector and operable togenerate a positioning signal that is detectable proximate a secondsurface of the workpiece on an opposite side from the first surface; afastener feed unit operable with the automated machine to deliver thefasteners through the end effector and into the workpiece; and acontroller that positions and activates the automated machine, the endeffector, and the fastener feed unit.
 11. The apparatus according toclaim 10, wherein the fastener feed unit further comprises: a fastenerstorage device; an unloading mechanism in communication with thefastener storage device; and a delivery conduit in communication withthe unloading mechanism and the automated machine, wherein thecontroller activates the unloading mechanism to retrieve at least onefastener from the fastener storage device, thereby causing the fastenerto be transported through the delivery conduit and to the end effector.12. The apparatus according to claim 10, wherein the automated machinefurther comprises: a guide structure fixed relative to the workpiece,the guide structure comprising at least one guide member extending alongthe first surface; an end effector carriage mounted on the guidestructure and movable along the guide member, the end effector beingmounted on the carriage; and a fastener carriage mounted on the guidestructure and movable along the guide member, the fastener feed unitbeing mounted on the carriage.
 13. The apparatus according to claim 12,wherein the guide structure comprises a pair of parallel guides alongwhich the carriages move.
 14. The apparatus according to claim 12,wherein the guide structure is releasably attachable to the workpiece.15. The apparatus according to claim 10, wherein the fastener storagedevice further comprises at least one fastener cassette that isremovably disposed within the fastener feed unit.
 16. The apparatusaccording to claim 15, wherein the fastener cassette further comprises aplurality of fastener storage tubes that house a plurality of fastenerconfigurations.